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! CAUTION

4. Loosely install the two nuts which secure the

cylinder to the crankcase.

The cylinder should slide on easily. Do not force

the cylinder or damage to the piston, rings,

cylinder, or crankshaft assembly may occur.

NOTE: The two cylinder to crankcase nuts will be

tightened in step 10.

Fig. 3-218

Fig. 3-219

CC525D

CC380D

C. Cylinder Head

D. Valve Cover

Fig. 3-220

KEY

1. Cylinder Head Assy

2. Valve Guide

3. O-Ring

4. Pin

5. Cap Screw

6. Cap Screw

7. Cylinder Head Gasket

8. Pin

9. Gasket

10. Nut

11. Nut

12. Gasket

13. Stud Bolt

14. Spark Plug

15. Inspection Cap

16. O-Ring

17. Cylinder Head Plug

18. Intake Pipe Assy

19. O-Ring

20. Cap Screw

21. Clamp

22. Gasket

0733-743

NOTE: Steps 1-4 in the preceding sub-section

must precede this procedure.

5. Place the chain guide into the cylinder.

! CAUTION

Care should be taken that the bottom of the

chain guide is secured in the crankcase boss.

3-46

Fig. 3-221

Fig. 3-224

CC379D

CC377D

6. On the 300 cc only, install the O-ring onto the front

left-side stud.

9. Loosely install the remaining cylinder head nuts.

Fig. 3-225

Fig. 3-222

CC376D

CC384D

10. In a crisscross pattern, tighten the three cylinder

head cap nuts and one nut to 2.5 kg-m (18 ft-lb).

Tighten the remaining head nuts and the

cylinder-to-crankcase nuts to 1.1 kg-m (8 ft-lb).

7. Place the head gasket into position on the cylinder.

Place the alignment pins into position; then place

the head assembly into position on the cylinder

making sure the chain is routed through the chain

cavity.

11. Place the C-ring into position in its groove in the

cylinder head.

Fig. 3-223

Fig. 3-226

CC378D

CC374D

8. Install the three cylinder head cap nuts and one nut

with copper washers (note the locations of the cap

nuts and nut). Tighten only until snug.

12. Install the chain tensioner pad into the cylinder

head.

3-47

Fig. 3-227

Fig. 3-229

CC375D

CC401D

NOTE: At this point, oil the camshaft bearings,

cam lobes, and the three seating journals on the

cylinder.

NOTE: When the camshaft assembly is seated,

make sure the alignment pin in the camshaft aligns

with the smallest hole in the sprocket.

13. With the alignment pin installed in the camshaft and

the cam lobes directed down (toward the piston),

place the camshaft in its seating position; then loop

the chain over the sprocket and install the sprocket

onto the camshaft.

Fig. 3-230

Fig. 3-228

CC402D

CC373D

14. When the camshaft assembly is seated, ensure the

following.

A. Piston still at top-dead-center.

B. Camshaft lobes directed down (toward the piston).

C. Camshaft alignment marks parallel to the valve

cover mating surface.

D. Recessed side of the sprocket directed toward the

cam lobes.

E. Camshaft alignment pin and sprocket alignment

hole (smallest) are aligned.

NOTE: Note the position of the alignment marks

on the end of the camshaft. They must be parallel

with the valve cover mating surface. If rotating the

camshaft is necessary for alignment, do not allow

the chain and sprocket to rotate and be sure the cam

lobes end up in the down position.

! CAUTION

If any of the above factors are not as stated, go

back to step 13 and carefully proceed.

15. Place the tab washer onto the sprocket making sure

it covers the pin in the alignment hole.

3-48

Fig. 3-231

18. Remove the cap screw from the end of the chain

tensioner. Account for the plunger, spring, and

O-ring.

Fig. 3-234

ATV1027

! CAUTION

CC405D

Care must be taken that the tab washer is

installed correctly to cover the alignment hole on

the sprocket. If the alignment pin falls out, severe

engine damage will result.

19. Depress the spring-loaded lock and push the

plunger into the tensioner.

Fig. 3-235

Fig. 3-232

CC406D

CC403D

20. Place the chain tensioner assembly and gasket into

the cylinder making sure the ratchet side is facing

toward the top of the cylinder and secure with the

two Allen-head cap screws.

16. Install the first cap screw (coated with red Loctite

#271) securing the sprocket and tab washer to the

camshaft. Tighten only until snug.

Fig. 3-236

Fig. 3-233

CC370D

CC404D

21. Install the cap screw into the end of the chain

tensioner.

17. Install the cylinder head plug in the cylinder head.

3-49

Fig. 3-237

Fig. 3-239

CC369D

CC408D

22. Rotate the crankshaft until the second cap screw

securing the sprocket to the camshaft can be

installed; then install the cap screw (coated with red

Loctite #271) and tighten to 1.15 kg-m (8.5 ft-lb).

Bend the tab to secure the cap screw.

26. Place the valve cover into position.

NOTE: At this point, the rocker arms and adjuster

screws must not have pressure on them.

27. Install the top side cap screws into the head noting

the locations of any with rubber washers; then

install the remaining cap screws. Tighten only until

snug.

23. Rotate the crankshaft until the first cap screw

securing the sprocket to the camshaft can be

addressed; then tighten to 1.15 kg-m (8.5 ft-lb).

Bend the tab to secure the cap screw.

Fig. 3-240

24. Loosen the adjuster screw jam nuts; then loosen the

adjuster screws on the rocker arms in the valve

cover.

Fig. 3-238

CC367D

28. In a crisscross pattern starting from the center and

working outward, tighten the cap screws to 1 kg-m

(7 ft-lb).

CC407D

29. Adjust valve/tappet clearance using the following

procedure.

25. Apply a thin coat of Three Bond Sealant (p/n

0636-070) to the mating surface of the valve cover.

NOTE: Use Valve Gap Adjuster (p/n 0444-092) for

this procedure.

A. Turn the engine over until the piston reaches top

dead center on the compression stroke.

B. Place the valve adjuster onto the jam nut securing

the tappet adjuster screw; then rotate the valve

adjuster dial clockwise until the end is seated in the

tappet adjuster screw.

C. While holding the valve adjuster dial in place, use

the valve adjuster handle and loosen the jam nut;

then rotate the tappet adjuster screw clockwise

until friction is felt.

3-50

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